Fulltext TSBs

Technical Service Bulletins

TSB
04-8-3
  • ELECTRICAL – SPLICING NEW WIRE(S) INTO EXISTING ELECTRICAL HARNESS – SERVICE PROCEDURE
Publication Date: April 19, 2004

FORD:
2000-2004 F-150

ISSUE:

If an unreliable method of wire splicing is used when installing alarms or other electrical add-on equipment, it may cause electrical systems to malfunction by creating variable resistance or a short circuit. Variable resistance can result from oxidation/corrosion caused by air within the joint, and a short circuit can result from moisture on the circuit joint or a frayed wire contacting another wire. Crimp-connectors are not a robust method for splicing in new wires and should not be used.

ACTION:

When splicing a new wire into an existing harness, use proper soldering and shrink-wrapping procedures as outlined below. Ford Dealerships should also advise companies performing sublet work (alarm, audio, etc.) to follow these same procedures. Rosin core solder and heat shrink tubing containing hot melt wax, MUST be used when splicing a new wire into an existing harness wire.

SERVICE PROCEDURE

  1. Strip 38 mm (1.5″) of insulation from the NEW WIRE being spliced into the existing wire.
  2. Cut the existing wire at a suitable point, and strip 19 mm (0.75″) of insulation from existing wire section A, and strip 38 mm (1.5″) from existing wire section B (Figure 1).

    NOTE:PULL WIRE STRAIGHT THROUGH STRIPPER. IF WIRE IS PULLED AT AN ANGLE, WIRE STRANDS MAY BE CUT OFF. IF MORE THAN ONE (1) STRAND IS CUT OFF DURING STRIPPING, CUT OFF WIRE END AND RE-STRIP.

    NOTE:THE ROTUNDA ULTRA-TORCH (107-R0304) IS A CORDLESS SOLDERING IRON/HEAT GUN RECOMMENDED TO BE USED FOR SOLDERING AND HEAT SHRINKING (STEPS 3 AND 5).

  3. Install the heat shrink tubing containing hot melt wax BEFORE SOLDERING (Figure 2). Twist together and solder the wires. SOLDER MUST BE ROSIN CORE MILDLY ACTIVATED (RMA) SOLDER. DO NOT USE ACID CORE SOLDER.
  4. Form (bend) the circuit into a shape for sealing, and position heat shrink tubing CONTAINING HOT MELT WAX over splice (Figure 3). It is important to position the heat shrink tubing centrally over the soldered joint to create a waterproof and airtight connection.

    NOTE:DURABILITY OF A HEAT SHRINK TUBING SPLICE IS DEPENDENT ON THE HOT MELT WAX THAT WILL APPEAR FROM BOTH ENDS OF THE TUBE. THE HOT MELT WAX FORMS AN ADHESIVE SEAL BETWEEN THE WIRE INSULATION AND THE HEAT SHRINK TUBING WHICH PREVENTS AIR AND MOISTURE FROM ENTERING THE SOLDER POINT.

  5. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing. Visually inspect for a robust seal.
  6. Re-tape the harness exterior with black plastic tape, and reinstall the wiring harness, ensuring that the harness and the new protruding wire do not get pinched or crushed.

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Information Only




Figure 1 – Article 04-8-3




Figure 2 – Article 04-8-3




Figure 3 – Article 04-8-3


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2004 Ford Motor Company